Title: Research on the ultra-precision ductile cutting mechanism of KDP crystal

Authors: Pengqiang Fu; Feihu Zhang; Chenhui An; Qiang Zhang

Addresses: School of Mechatronics Engineering, Harbin Institute of Technology, 150001, Harbin, China. ' School of Mechatronics Engineering, Harbin Institute of Technology, 150001, Harbin, China. ' Research Center of Laser Fusion, Chinese Academy of Engineering Physics, 621900, Mianyang, China. ' School of Mechatronics Engineering, Harbin Institute of Technology, 150001, Harbin, China

Abstract: To achieve ductile processing of brittle materials is a key factor to obtain high quality finished surface. A new strategy was carried to clarify the brittle-to-ductile transition mechanism. The KDP crystal was processed by a mono diamond tool with arc-nose, and the plastic deformation can be found in the inside chip by optical microscope, also apparent transitional zone of brittle fracture to plastic deformation along the width direction of chips. It can be inferred that the width of plastically deforming area is sensitive to the cutting parameter feedrate. The critical cutting thickness was calculated by the parameters measured from the chips. At last a new model for calculating the critical cutting thickness of KDP crystal was given.

Keywords: KDP crystals; brittle-to-ductile transition; critical cutting thickness; chip morphology; single point diamond fly cutting; SPDFC; brittle materials; cutting mechanism; chip deformation; nanomanufacturing; nanotechnology; ductile processing; surface roughness; surface quality; potassium dihydrogen phosphate; modelling.

DOI: 10.1504/IJNM.2011.042467

International Journal of Nanomanufacturing, 2011 Vol.7 No.3/4, pp.214 - 222

Received: 12 Nov 2010
Accepted: 07 Mar 2011
Published online: 07 Mar 2015 *

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